IOSI supports research at all technology readiness levels, including proof-of-concept, with a clear line-of-sight towards technology commercialization in oil sands mining operations, in the four research themes: Extraction, Smart Mining, Tailings, and Value-Added Products. The current focus areas are described below.
Focus 2024: Aqueous bitumen extraction optimization
Background
Mined oil sands industry uses a water-based extraction process to separate bitumen from oil sands ore. Here the mined oil sands – after being crushed – are mixed with hot process water and caustic to form a slurry. The slurry is transferred to separation vessels via hydrotransport lines where ore lumps are mechanically sheared, and bitumen gets aerated. The aerated bitumen is separated in the form of froth in the primary separation cell. The unrecovered bitumen is subjected to air flotation. Kearl Oil Sands uses Paraffin Froth Treatment (PFT) process to separate bitumen from water and solids. Over 90% of bitumen recovery can be achieved in the water-based process depending on the ore grade and the processing conditions.
Another strategic direction of this theme is to enable Satellite Pit Froth Production. As the mine site expands, new, mobile extraction systems need to be developed and installed at satellite locations from the central processing facility to avoid hauling mined oil sands dozens of kilometres for processing.
For more general information on the extraction process, including at Imperial Oil, please refer to:
Technology and Knowledge Gaps
Preferred Processes and Methods
2024 Focus: Measurements for extraction plant optimization
Background
Mined oil sands industry uses a water-based extraction process to separate bitumen from oil sands ore. Here the mined oil sands – after being crushed – are mixed with hot process water and caustic to form a slurry. The slurry is transferred to separation vessels via hydrotransport lines where ore lumps are mechanically sheared, and bitumen gets aerated. The aerated bitumen is separated in the form of froth in the primary separation cell. The unrecovered bitumen is subjected to air flotation. Kearl Oil Sands uses Paraffin Froth Treatment (PFT) process to separate bitumen from water and solids. Over 90% of bitumen recovery can be achieved in the water-based process depending on the ore grade and the processing conditions.
The extraction plant operation relies on the accurate measurements of components of interest in the process streams. Online instrumentation, as well as fast ex-situ measurements, minimize response time, which translates into a stable plant performance with improved bitumen yield, reduced GHG emissions, water consumption and volume of rejected tailings.
For more information on the extraction process, including at Imperial Oil, refer to the links provided below:
Technology and Knowledge Gaps
Preferred Processes and Methods
The research in this Theme is carried out in collaboration with Canada’s Oil Sands Innovation Alliance (COSIA).
No open call for proposals.
2024 Focus: VAP from TSRU tailings for construction. Carbon separation from TSRU tailings.
Background
Alberta’s oil sands offer a unique opportunity to diversify products of their exploitation beyond fuel to innovative materials with commercialization potential.
The rejected stream of interest is TSRU tailings. Mined oil sands industry uses Paraffin Froth Treatment (PFT) process to separate bitumen from water and solids: https://www.oilsandsmagazine.com/technical/mining/froth-treatment/paraffinic. The rejected tailing stream from the tailing solvent recovery unit (TSRU) of PFT contains about 75-80% water, 15-20% minerals, 4% asphaltenes, 1% maltenes, <0.1% paraffinic solvent. There must be economic and environmental benefits to converting TSRU tailings into valuable products. Two research priorities were identified as: VAP for construction, and carbon separation.
VAP for construction
Background: earlier IOSI projects addressed proof-of-concept studies on the potential use of TSRU tailings in pavement construction and as additives for cement-based construction materials. Further research is required to advance TRL and address the challenges.
Challenges:
Carbon separation from TSRU tailings
Background: carbonaceous material in TSRU tailings may be converted to carbon VAP via thermal and/or catalytic processes. However, the dry TSRU tailings consist mostly of minerals, which negatively impacts the energy requirement for conversion and final product quality.
Challenges:
These methods should present a viable pathway to a commercial process with low energy intensity, low GHG emissions, low waste production (ideally, solvent-free methods), with a low footprint and potential pilot or small commercial demonstration within 5 years. The preferable feedstock is wet TSRU tailings, before or after separation by gravity.
Excluded challenges for this Call:
